Additive Manufacturing Build Materials for Consistent Multi-Material Printing
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Solution Overview
Problem
Existing additive manufacturing technologies face challenges in efficiently switching between multiple build materials during a single printing process, leading to impractical material changes and complex property variations in 3D articles.
Innovation Solution
A kit comprising non-identical build materials with similar or differing properties, allowing for multi-material printing without changing printing parameters, enabling complex property profiles in a single printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple build materials with different compositions are used in a single printing process, then the functional versatility and property variation of the 3D article is improved, but the complexity of material switching and process control increases
Solution Approach 1:
The patent applies parameter changes by systematically varying the composition of build materials (different resins, monomers, photoinitiators, additives) while maintaining consistent printing parameters. This allows functional versatility to be improved through material composition changes without increasing device complexity, as the printing process parameters remain unchanged across different materials.
Solution Approach 2:
The patent implements universality by developing a platform approach where a single additive manufacturing system can process multiple build materials with different compositions and properties. The system uses a universal set of printing parameters that work across different material types, enabling one device to perform multiple functions with various materials without requiring complex material-specific adjustments.
2Adaptability or versatility
If material composition is changed frequently during printing, then the property variation in different regions of the 3D article is improved, but the manufacturing precision and consistency of printing parameters deteriorate
Solution Approach 1:
The patent applies local quality by enabling different build materials with specific compositions to be deposited in different spatial regions of the 3D article. Each region can have tailored material properties (mechanical, optical, thermal) while the printing parameters remain consistent, achieving local property variation without sacrificing manufacturing precision.
Solution Approach 2:
The patent resolves this contradiction by changing material composition parameters rather than printing process parameters. This allows property variation in different article regions through material selection while maintaining consistent printing parameters, thus preserving manufacturing precision.
3Reliability
If different build materials are used to achieve desired properties, then the functional performance of the 3D article is improved, but the number of material changes required during printing increases
Solution Approach 1:
The patent improves functional performance through parameter changes in material composition (resin type, monomer selection, photoinitiator concentration, additive packages) while maintaining consistent printing parameters. This reduces the number of material changes required during printing, as a single build material can be optimized to achieve multiple functional requirements.
Solution Approach 2:
The patent applies composite materials by formulating build materials that contain multiple components (resins, monomers, photoinitiators, additives) working together to achieve desired functional properties. This allows complex functional performance to be achieved within a single build material, reducing the need for frequent material changes during printing and improving productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient multi-material printing with controlled spatial variations in 3D articles, maintaining consistent printing parameters across material transitions.
Implementation Method 1
the build material is solid at ambient temperatures, and converts to liquid at elevated jetting temperatures
Implementation Method 2
the build material can be cured following dispensing and/or deposition thereof onto the substrate. Curing can be achieved using a laser or other source of electromagnetic radiation
Implementation Method 3
a binder material or a laser or other source is used to selectively solidify or consolidate layers of the build material in a stepwise fashion to provide the 3D article
Data Source
AI summary
In one aspect, a kit for use in additive manufacturing is provided, the kit comprising a first build material and a second build material, wherein the first build material and the second build material do not have identical chemical compositions, and wherein the first build material and the second build material have at least one property that differs by 10% or less. In another aspect, a method of printing a three-dimensional article is provided, the method comprising providing a first build material and a second build material, and selectively consolidating or solidifying layers of the first build material and layers of the second build material to form the 3D article.